Methods for passivating a carbonic nanolayer

ABSTRACT

Methods for passivating a carbonic nanolayer (that is, material layers comprised of low dimensional carbon structures with delocalized electrons such as carbon nanotubes and nano-scopic graphene flecks) to prevent or otherwise limit the encroachment of another material layer are disclosed. In some embodiments, a sacrificial material is implanted within a porous carbonic nanolayer to fill in the voids within the porous carbonic nanolayer while one or more other material layers are applied over or alongside the carbonic nanolayer. Once the other material layers are in place, the sacrificial material is removed. In other embodiments, a non-sacrificial filler material (selected and deposited in such a way as to not impair the switching function of the carbonic nanolayer) is used to form a barrier layer within a carbonic nanolayer. In other embodiments, carbon structures are combined with and nanoscopic particles to limit the porosity of a carbonic nanolayer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the earlier filing date of the following U.S. patent applications, the contents of which are incorporated by reference herein in their entireties:

Methods for Passivating a Nanotube Fabric Layer by Controlling the Density of the Nanotube Fabric Layer (U.S. Patent Application No. 61/254,588), filed Oct. 23, 2009;

Methods for Passivating a Nanotube Fabric Layer Through the Use of a Sacrificial Material (U.S. Patent Application No. 61/254,585), filed Oct. 23, 2009;

Methods for Passivating a Nanotube Fabric Layer Through the Use of a Non-Sacrificial Material (U.S. Patent Application No. 61/254,596), filed Oct. 23, 2009; and

Methods for Passivating a Nanotube Fabric Layer Through the Use of Nanoscopic Particles (U.S. Patent Application No. 61/254,599), filed Oct. 23, 2009.

This application is also related to the following U.S. patents, which are assigned to the assignee of the present application, and are hereby incorporated by reference in their entirety:

Methods of Nanotube Films and Articles (U.S. Pat. No. 6,835,591), filed Apr. 23, 2002;

Methods of Using Pre-Formed Nanotubes to Make Carbon Nanotube Films, Layers, Fabrics, Ribbons, Elements, and Articles (U.S. Pat. No. 7,335,395), filed Jan. 13, 2003;

Spin-Coatable Liquid for Formation of High Purity Nanotube Films (U.S. Pat. No. 7,375,369), filed Jun. 3, 2004.

This application is related to the following patent applications, which are assigned to the assignee of the application, and are hereby incorporated by reference in their entirety:

Methods of Making Carbon Nanotube Films, Layers, Fabrics, Ribbons, Elements, and Articles (U.S. patent application Ser. No. 10/341,005), filed Jan. 13, 2003;

High Purity Nanotube Fabrics and Films (U.S. patent application Ser. No. 10/860,332), filed Jun. 3, 2004;

Two terminal Nanotube Devices and Systems and Methods of Making Same (U.S. patent application Ser. No. 11/280,786), filed Nov. 15, 2005;

Nanotube Articles with Adjustable Electrical Conductivity and Methods of Making the Same (U.S. patent application Ser. No. 11/398,126), filed Apr. 5, 2006;

Nonvolatile Nanotube Diodes and Nonvolatile Nanotube Blocks and Systems Using Same and Methods of Making Same (U.S. patent application Ser. No. 11/835,651), filed Aug. 8, 2007;

Nonvolatile Resistive Memories Having Scalable Two terminal Nanotube Switches (U.S. patent application Ser. No. 11/835,612), filed Aug. 8, 2007;

Nonvolatile Nanotube Diodes and Nonvolatile Nanotube Blocks and Systems Using Same and Methods of Making Same (U.S. patent application Ser. No. 11/835,856), filed Aug. 8, 2008;

Memory Elements and Cross Point Switches and Arrays of Same Using Nonvolatile Nanotube Blocks (U.S. patent application Ser. No. 12/511,779), filed Jul. 29, 2009;

Nonvolatile Nanotube Diodes and Nonvolatile Nanotube Blocks and Systems Using Same and Methods of Making Same (U.S. patent application Ser. 12/273,807), filed Nov. 19, 2008;

Improved Switching Materials Comprising Mixed Nanoscopic Particles and Carbon Nanotubes and Methods of Making and Using Same (U.S. patent application Ser. No. 12/274,033), filed Nov. 19, 2008;

Methods for Controlling Density, Porosity, and/or Gap Size Within Nanotube Fabric Layers and Films (U.S. Patent App. No. 61/304,045), filed Feb. 12, 2010;

Methods for Reducing Gaps and Voids within Nanotube Layers and Films (U.S. Patent App. No. 61/350,263), filed Jun. 17, 2010.

TECHNICAL FIELD

The present disclosure relates to carbonic nanolayers, and more particularly to methods of passivating carbonic nanolayers such as to prevent or otherwise limit the encroachment or penetration other materials into or through such carbonic nanolayers.

BACKGROUND OF THE INVENTION

Any discussion of the related art throughout this specification should in no way be considered as an admission that such art is widely known or forms part of the common general knowledge in the field.

Carbonic nanolayers offer a plurality of uses within commercial electronics. For example, nanotube based switching devices can be used as nonvolatile memory devices, combined to form logic devices, and used to form analog circuit elements such as, but not limited to, nanotube based field effect transistors and programmable power supplies. In particular, two terminal nanotube based switching devices are becoming increasingly desirable within electronic systems—such as, but not limited to, memory arrays, microprocessors, and FPGAs—and arrays of such devices are continually increasing in complexity and density, creating a need for smaller and smaller individual devices.

As the demand for smaller scale carbonic nanolayer based devices grows there is an increasing need for improved manufacturability of such devices. In particular, there is an increasing need to develop processes that limit or otherwise prevent the encroachment or penetration of material layers deposited or otherwise formed above or alongside relatively thin or narrow carbonic nanolayers.

SUMMARY OF THE DISCLOSURE

The current invention relates to the passivation of carbonic nanolayers.

In particular, the present disclosure provides a carbonic nanolayer based device. The carbonic nanolayer based device comprises a carbonic nanolayer, the carbonic nanolayer comprising a plurality of carbon structures and having a first side and a second side. The carbonic nanolayer further comprises a material layer. The carbonic nanolayer and the material layer have longitudinal axes that are substantially parallel. And the density of the carbonic nanolayer is selected such as to limit the encroachment of the material layer into the carbonic nanolayer.

The present disclosure also provides a method for forming a carbonic nanolayer based device. The method comprises first forming a carbonic nanolayer, this carbonic nanolayer comprising a plurality of carbon structures. The method further comprises flowing a filler material over the carbonic nanolayer such that the filler material penetrates the carbonic nanolayer to form a barrier layer. The method further comprises depositing a material layer such that the carbonic nanolayer and the second material layer have longitudinal axes that are substantially parallel.

The present disclosure also provides a method for forming a carbonic nanolayer based device. The method comprises combining a first volume of carbon structures and a second volume of nanoscopic particles in a liquid medium to form an application solution. The method further comprises depositing the application solution over a first material layer as to form a composite layer, the composite layer comprising a mixture of the carbon structures and the nanoscopic particles. The method further comprises depositing a second material layer such that the composite layer and the second material layer have longitudinal axes that are substantially parallel.

The present disclosure also provides a nanotube switching device. This nanotube switching device comprises a first conductive element, a second conductive element, and a nanotube fabric layer which includes a plurality of individual nanotube elements. The nanotube fabric layer includes a first side and a second side, wherein the first side of the nanotube fabric layer is electrical coupled to the first conductive element and the second side of said nanotube fabric layer is electrically coupled to the second conductive element. The density of the nanotube fabric layer is selected such as to limit the encroachment of at least one of the first conductive element and the second conductive element into the nanotube fabric layer.

According to one aspect of the present disclosure the density of a carbonic nanolayer is selected in order to limit encroachment of other material layers.

According to another aspect of the present disclosure a sacrificial material is used to form a barrier layer within a carbonic nanolayer during a manufacturing process.

According to another aspect of the present disclosure a non-sacrificial filler material is used to form a barrier layer within a carbonic nanolayer.

According to another aspect of the present disclosure nanoscopic particles are mixed with carbon structures to form a composite carbonic nanolayer material.

According to another aspect of the present disclosure a filler material is comprised of phosphosilicate glass (PSG) oxide, amorphous carbon, silicon dioxide (SiO2), or silicon nitride (SiN).

According to another aspect of the present disclosure a porous dielectric (such as silicon dioxide aerogel or porous silica) is used as a filler material.

According to another aspect of the present disclosure a carbonic nanolayer is comprised of carbon nanotubes.

According to another aspect of the present disclosure a carbonic nanolayer is comprised of buckyballs.

According to another aspect of the present disclosure a carbonic nanolayer is comprised of graphene sheets.

According to another aspect of the present disclosure a carbonic nanolayer is comprised of nano-scopic graphene flecks.

Other features and advantages of the present invention will become apparent from the following description of the invention which is provided below in relation to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration depicting a first two terminal nanotube switching device comprising a nanotube fabric layer of thickness T₁;

FIG. 2 is an illustration depicting a second two terminal nanotube switching device comprising a nanotube fabric layer of thickness T₂;

FIG. 3 is an illustration depicting a two terminal nanotube switching device comprising a low density nanotube fabric layer with a relatively high porosity;

FIG. 4 is an illustration depicting a two terminal nanotube switching device wherein the porosity of nanotube fabric layer has been selected by limiting the length of the individual nanotube elements comprising the nanotube fabric layer;

FIG. 5 is an illustration depicting a two terminal nanotube switching device wherein the porosity of nanotube fabric layer has been selected through the use of a specific application method;

FIG. 6 is an illustration depicting a two terminal nanotube switching device comprising multiple nanotube fabric layers;

FIGS. 7A-7J are a series of process diagrams which illustrate a method of passivating a nanotube fabric layer through the use of a sacrificial filler material;

FIGS. 8A-8K are a series of process diagrams which illustrate a method of passivating a nanotube fabric layer through the use of a sacrificial filler material wherein the sacrificial material is volatized and removed through a non-hermetic material layer;

FIGS. 9A-9M are a series of process diagrams which illustrate a method of passivating a nanotube fabric layer through the use of a sacrificial filler material wherein the sacrificial material is volatized during the formation of the individual two terminal nanotube switching elements within an array;

FIGS. 10A-10D are a series of process diagrams which illustrate a method of passivating a nanotube fabric layer through the use of a non-sacrificial filler material;

FIGS. 11A-11F are a series of process diagrams which illustrate a method of passivating a nanotube fabric layer through the use of a porous dielectric material.

FIGS. 12A-12F are a series of process diagrams which illustrate a method of passivating a nanotube fabric layer through the use of a room temperature chemical vapor deposition (RTCVD) process;

FIGS. 13A-13E are a series of process diagrams which illustrate a method of passivating a nanotube fabric layer through the use of a non-directional sputter deposition process;

FIG. 14 is a process diagram illustrating a the formation of a passivated two terminal nanotube switching device which includes a nanotube fabric layer which comprises both individual nanotube elements and nanoscopic particles;

FIGS. 15A-15F is a process diagram illustrating a method of further passivating a nanotube fabric layer comprised of individual nanotube elements and nanoscopic particles through the use of a room temperature chemical vapor deposition (RTCVD) process;

FIGS. 16A-16E is a process diagram illustrating a method of further passivating a nanotube fabric layer comprising individual nanotube elements and nanoscopic particles through the use of a non-directional sputter deposition process.

DETAILED DESCRIPTION

The present disclosure involves the passivation of carbonic nanolayers. As will be shown in the following discussion of the present disclosure, carbonic nanolayers can be passivated—that is formed or prepared in such a way as to prevent or otherwise limit the encroachment of another material layer—in a plurality of ways. Other material layers may include conductive materials, such as, but not limited to, Tungsten (W), copper (Cu), and Platinum (PT), or nonconductive material layers such as plastic.

Within the present disclosure, carbonic nanolayers are defined as material layers comprising low dimensional carbon structures with delocalized electrons. It should be noted that while many of the examples within the present disclosure utilize carbonic nanolayers as exemplary carbonic nanolayers, the methods of the present disclosure are not limited in this regard. Indeed, as described above carbonic nanolayers may be comprised of any low dimensional carbon structure with delocalized electrons. Such carbon structures include, but are not limited to, single wall and multi-wall carbon nanotubes (or portions thereof), functionalized carbon nanotubes, oxidized carbon nanotubes, buckyballs, graphene sheets, nano-scopic graphene flecks, and graphene oxide.

In some aspects of the present disclosure, a carbonic nanolayer can be passivated by increasing the density of the layer by adjusting one or more characteristics of the carbon structures (such as, but not limited to, carbon nanotubes, buckyballs, nano-scopic graphene flecks) contained in the nanotube fabric layer (e.g., length, orientation, etc.). This increased density limits the porosity of the carbonic nanolayer, thereby limiting the depth to which another material layer can penetrate.

In some aspects of the present disclosure, a sacrificial material is implanted within a porous carbonic nanolayer during the fabrication process. This sacrificial material is used to fill in the voids and gaps within the carbonic nanolayer while one or more other material layers are applied over or alongside the carbonic nanolayer. Once the other material layers are in place, the sacrificial material is removed, allowing the carbonic nanolayer to function.

In other aspects of the present disclosure, a non-sacrificial filler material is used to passivate a carbonic nanolayer. Within these aspects of the present disclosure, a filler material is selected and deposited within a carbonic nanolayer in such a way as to not adversely affect the switching function of the carbonic nanolayer. In this way, a barrier layer is formed within the porous carbonic nanolayer which prevents an adjacent material layer from fully penetrating through the carbonic nanolayer.

In other aspects of the present disclosure, a carbonic nanolayer is formed comprising a first plurality of carbon structures and a second plurality of nanoscopic particles. The second plurality of nanoscopic particles serves to limit the porosity of the carbonic nanolayer, thereby limiting the encroachment of adjacent material layers into the carbonic nanolayer. The nanoscopic particles are selected and combined with the carbon structures in such a way as to not adversely affect the switching operation of the carbonic nanolayer.

Each of these aspects will be described in the following sections in accordance with the accompanying figures.

U.S. patent application Ser. No. 11/280,786 to Bertin et. al, incorporated herein by reference, teaches the fabrication of such two terminal nanotube switching devices. As taught by Bertin, a two terminal switching device includes a first and second conductive terminals and a nanotube article (that is, a network of carbon nanotube elements which form a carbonic nanolayer). The nanotube article overlaps a portion of each of the first and second conductive terminals. In at least some embodiments described by Bertin, the nanotube article is a nanotube fabric layer disposed over the first conductive terminal. In such embodiments the second conductive terminal is disposed over the nanotube fabric layer, forming a three layer device with the nanotube fabric layer substantially between the first and second conductive elements.

Bertin further describes methods for adjusting the resistivity of the nanotube fabric layer between a plurality of nonvolatile resistive states. In at least one embodiment, electrical stimuli is applied to at least one of the first and second conductive elements such as to pass an electric current through said nanotube fabric layer. By carefully controlling these electrical stimuli within a certain set of predetermined parameters (as described by Bertin in Ser. No. 11/280,786) the resistivity of the nanotube fabric layer can be repeatedly switched between a relatively high resistive state and relatively low resistive state. In certain embodiments, these high and low resistive states can be used to store a digital bit of data (that is, a logic “1” or a logic “0”).

FIG. 1 illustrates a first two terminal nanotube switching device 100 similar to the device taught by Bertin. In certain embodiments, a nanotube fabric layer 130 (of thickness T₁) is deposited over a first conductive element 110 in a first operation. In a second operation, a second conductive element 120 is deposited over the nanotube fabric layer 130. As depicted in FIG. 1, as the second conductive element 120 is applied, the second conductive element 120 may seep partially into the porous nanotube fabric layer 130. Typically such penetration is not problematic or detrimental to the operation of two terminal nanotube switching device 100 as the thickness (T₁) of the nanotube fabric layer 130 is significantly larger than the depth of the penetration. That is, while second conductive element 120 seeps partially into porous nanotube fabric layer 130, the nanotube fabric layer 130 is thick enough to prevent an electrical short between the first conductive element 110 and the second conductive element 120.

FIG. 2 illustrates a second two terminal nanotube switching device. Two terminal nanotube switching device 200 (as depicted in FIG. 2) is intended to illustrate a switching device fabricated on a significantly smaller scale as compared with the two terminal nanotube switching device 100 depicted in FIG. 1. Nanotube fabric layer 230 (of thickness T₂) is deposited over a first conductive element 210 in a first operation. In a second operation, a second conductive element 220 is deposited over nanotube fabric layer 230. As with the two terminal nanotube switching device 100 depicted in FIG. 1, the second conductive element 220 may seep partially into the porous nanotube fabric layer 230. However, in certain embodiments, as nanotube fabric layer 230 is relatively thin, second conductive element 220 can substantially penetrates all the way through porous nanotube fabric layer 230, effectively forming an electrical short circuit between first conductive element 210 and second conductive element 220.

In one non-limiting example, T₁ (the thickness of the nanotube fabric layer 130) is on the order of 100 nm, while T₂ (the thickness of the nanotube fabric layer 230) is on the order of 20 nm. In another non-limiting example, T₂ would be on the order of 5 nm. It should be noted that while these exemplary thickness values are intended to illustrate a specific fabrication issue as two terminal nanotube switching devices are realized on increasingly smaller scales, this fabrication issue is not limited to these dimensions. Further, a plurality of factors may contribute to the depth of which a conductive element will penetrate into a nanotube fabric layer over which it is deposited. Such factors include, but are not limited to, the density of the nanotube fabric layer, the method used to deposit the overlying conductive layer, and the material used to form the overlying conductive layer.

As described in the preceding discussion, FIG. 2 illustrates a potential limitation as the physical dimensions of two terminal nanotube switches are reduced. Nanotube fabrics can be porous and can be susceptible to penetration by a material deposited over them. Further, the performance of nanotube fabric layers within such switching devices can be degraded by certain materials, gases, or contaminants. For example, oxygen and water can react with CNTs at high temperatures. Carbon nanotubes can also be functionalized with other contaminating materials—such as, but not limited to, fluorine and chlorine—which may also deteriorate the operational parameters of a nanotube fabric layer by altering the electrical properties of the individual carbon nanotubes elements within the fabric and carbon nanotube. Furthermore, without wishing to be bound by theory, within a two terminal nanotube switching device, the nanometer-level motion of the individual nanotube elements may desirably remain unhindered by the surrounding device structure.

As such, certain embodiments of the present invention provides a method of two terminal nanotube switch fabrication which provides a physical barrier (a passivation layer) adjacent to or within the nanotube fabric layer such that adjacent material layers as well as other contaminants are prevented from penetrating the nanotube fabric layer. Certain embodiments of the present invention further advantageously provide this method without interfering with or otherwise adversely affecting the switching operation of the nanotube fabric layer.

Within the methods of the present disclosure, nanotube fabric layers can be formed over substrate elements. The methods include, but are not limited to, spin coating (wherein a solution of nanotubes is deposited on a substrate which is then spun to evenly distribute said solution across the surface of said substrate), spray coating (wherein a plurality of nanotube are suspended within an aerosol solution which is then disbursed over a substrate), and in situ growth of nanotube fabric (wherein a thin catalyst layer is first deposited over a substrate and then used to form nanotubes). (See, e.g., U.S. Pat. No. 7,335,395 to Ward et al., which is incorporated herein by reference in its entirety.) U.S. Pat. No. 7,375,369 to Sen et al., and U.S. Patent Publication No. 2006/0204427, both of which are incorporated herein by reference in its entirety, teach nanotube solutions which is well suited for forming a nanotube fabric layer over a substrate element.

It should also be noted that while the figures within the present disclosure (as well as the accompanying description of those figures) depict substantially vertically oriented two terminal nanotube switching devices—that is, a nanotube fabric layer positioned between a first conductive element below and a second conductive element above—the methods of the present disclosure are not limited in this regard. Indeed, as is described in the incorporated references (most notably U.S. patent application Ser. No. 11/835,651 to Bertin et. al., incorporated herein by reference in its entirety) two terminal nanotube switching devices can be formed within a plurality of orientations, including, but not limited to, vertical, horizontal, two dimensional (wherein a nanotube fabric layer is in contact with two or more electrode elements substantially in the same plane), and disposed over one or more flexible electrode elements. It will be clear to those skilled in the art that the methods of the present disclosure (as described below with respect to substantially vertical two terminal switching devices for the sake of clarity) are applicable to two terminal nanotube switching devices constructed in any of these orientations.

It should also be noted that while the figures within the present disclosure (as well as the accompanying description of those figures) describe the passivation methods of the present disclosure within the scope of the fabrication of two terminal nanotube switching devices, the methods of the present disclosure are not limited in this regard. Indeed, the passivation methods of the present invention are directly applicable to the fabrication of a plurality of carbonic nanolayer based devices including, but not limited to, carbonic nanolayer based sensors, carbonic nanolayer based field effect transistors, and carbonic nanolayer based logic devices. Further, such carbonic nanolayer based devices can comprise any low dimensional carbon structure with delocalized electrons—such as, but are not limited to, single wall and multi-wall carbon nanotubes (or portions thereof), functionalized carbon nanotubes, oxidized carbon nanotubes, buckyballs, graphene sheets, nano-scopic graphene flecks, and graphene oxide.

Passivation Through the Use of Dense Fabric Layers

In one aspect of the present disclosure, a carbonic nanolayer is passivated by increasing the density of the carbon structures within the layer, such as by adjusting one or more characteristics of the carbon elements contained in the carbonic nanolayer (e.g., length, orientation, etc.). This increased density limits the porosity of the carbonic nanolayer, thereby limiting the depth to which an adjacent material layer can penetrate. Within this aspect of the present disclosure, the density of a nanotube fabric layer, for example, can be increased by limiting the length of the individual nanotube elements comprising the nanotube fabric layer (as depicted in FIG. 4), through the use of a specific application method—such as, but not limited to, spin coating—which deposits the individual nanotube elements in a dense fabric (as depicted in FIG. 5), or through the use of a top layer of individual nanotubes specially deposited to provide a densely packed barrier layer (as depicted in FIG. 6). Each of these methods is described in detail in the following discussion of FIGS. 3-6.

FIG. 3 illustrates a first two terminal nanotube switching device 301 comprising a porous nanotube fabric layer 330 deposited over a first conductive layer 310. Porous nanotube fabric layer 330 is comprised of a plurality of individual nanotube elements 330 a, all of which are substantially the same length. A second conductive layer 320 is deposited over porous nanotube fabric layer 330. As with the two terminal nanotube switching device depicted in FIG. 2 (200 in FIG. 2), the porosity of the nanotube fabric layer 330 is such that second conductive layer 320 is permitted to seep through the nanotube fabric layer 330 and make electrical contact with first conductive layer 310, essentially establishing a short circuit through nanotube fabric layer 330.

FIG. 4 illustrates another two terminal nanotube switching device 401 wherein the porosity of nanotube fabric layer 430 has been selected by limiting the length of the plurality of individual nanotube elements 430 a within nanotube fabric layer 430. The shorter individual elements 430 a form a significantly denser fabric layer 430 (as compared with nanotube fabric layer 330 in FIG. 3) as they are deposited over first conductive layer 410. In this way, the porosity of nanotube fabric layer 430 has been reduced such as to prevent second conductive layer 420 from seeping through nanotube fabric layer 430 and coming into physical or direct electrical contact with first conductive layer 410.

Within a non-limiting example, for instance, the individual nanotube elements 330 a of nanotube fabric layer 330 might be on the order of 1 μm, and the individual nanotube elements 430 a of nanotube fabric layer 430 might be on the order of nanometers, such as 500 nm, 300 nm, 200 nm, or 100 nm or even less.

FIG. 5 illustrates another two terminal nanotube switching device 501 wherein the porosity of nanotube fabric layer 530 has been selected through the use of a specific application method—such as, but not limited to, spin coating or dip coating—to form nanotube fabric layer 530 over first conductive layer 510.

Within a spin coating operation, individual nanotube elements 530 a may be suspended in a solvent in a soluble or insoluble form and spin-coated over a surface to generate a nanotube film. In such an arrangement the nanotube fabric layer created may be one or more nanotubes thick, depending on the spin profile and other process parameters. Appropriate solvents include, but are not limited to: dimethylformamide, n-methylpyrollidinone, n-methyl formamide, ethyl lactate, alcohols, water with appropriate surfactants such as sodium dodecylsulfate or TRITON X-100, water alone, anisol or other solvents. The nanotube concentration and deposition parameters such as surface functionalization, spin-coating speed, temperature, pH and time can be adjusted for controlled deposition of monolayers or multilayers of nanotubes as required.

The nanotube film could also be deposited by dipping a wafer or a substrate (such as first conductive layer 510) in a solution of soluble or suspended nanotubes (a dip coating process).

Both spin coating and dip coating allow for the formation of a nanotube fabric layer 530 which is significantly denser—and, in some embodiments, substantially uniform in density—than could be realized with other deposition methods. For example, spray coating—wherein a nanotube fabric is formed by spraying a plurality of individual nanotube elements in the form of an aerosol onto a surface—typically yields a nanotube fabric layer with a non-uniform density and comprising a plurality of voids which tend to allow the penetration of adjacent material layers.

In this way, a highly dense nanotube fabric layer 530 deposited through a spin coating or dip coating process will limit the penetration of an adjacent material layer, such as second conductive layer 520.

While the highly dense nanotube fabric layers depicted in FIG. 4 and FIGS. 5 (430 and 530, respectively) provide an effective passivation method, in some applications such a nanotube fabric layer may prove inconvenient or impractical to produce. A highly dense nanotube fabric layer (such as 430 in FIG. 4 or 530 in FIG. 5) uses significantly more individual nanotube elements than a comparatively less dense fabric layer of similar geometry (such as 330 in FIG. 3, for example), resulting in significantly higher fabrication costs. Moreover, a densely packed nanotube fabric layer will tend to possess a very low resistance range as compared to a less dense fabric layer of similar geometry, significantly limiting, in some applications, the nanotube fabric layer's usefulness within a two terminal nanotube switch. In some applications, therefore, a single highly dense nanotube fabric layer may not provide a complete solution to the problem of adjacent material layer penetration. To this end, FIG. 6 illustrates a two terminal nanotube switching device comprising multiple nanotube fabric layers.

Referring now to FIG. 6, a first nanotube fabric layer 630, comprising a plurality of individual nanotube elements 630 a, is deposited over a first conductive layer 610 in a first operation. In a second operation, a second nanotube fabric layer 640, comprising a plurality of individual nanotube elements 640 a, is deposited over the first nanotube fabric layer 630. The second nanotube fabric layer is formed with a relatively high density (as described in the discussions of FIGS. 4 and 5 above), preventing second conductive layer 620 from penetrating the second nanotube fabric layer.

In some embodiments of this aspect of the present disclosure, second nanotube fabric layer 640 includes a plurality of rafted nanotube elements. That is, wherein the second nanotube fabric layer 640 is deposited in such a manner that the individual nanotube elements 640 a are bundled together along their sidewalls, providing a highly dense fabric layer. The formation of such rafted nanotube fabric layers is taught within U.S. Patent App. No. 61/304,045 to Sen et al., incorporated herein by reference in its entirety. Sen teaches a plurality of methods for preparing a nanotube application solution well suited for forming a rafted nanotube fabric layer. Such methods include increasing the nanotube concentration of a nanotube application solution (that is, increasing the number of nanotubes per unit volume within an application solution) and limiting the concentration of ionic species (such as, but not limited to, nitrates) within a nanotube application solution.

In other embodiments of this aspect of the present disclosure, second nanotube fabric layer 640 includes a plurality of ordered nanotube fabric elements. That is, wherein the second nanotube fabric layer 640 comprises nanotube elements oriented in a substantially uniform arrangement such that they group together along their sidewalls. The formation of such ordered nanotube fabric layers is taught within U.S. Patent App. 61/350,263 to Roberts et al, incorporated herein by reference in its entirety. Roberts teaches a plurality of methods for rendering a nanotube fabric layer into a network of ordered nanotube elements including via the application of a directional mechanical force—such as, but not limited to, a rolling, rubbing, or polishing force—applied over an unordered (or partially ordered) nanotube fabric layer.

Within this aspect of the present disclosure, the density of the first nanotube fabric layer can be selected according to the needs of the specific application wherein this aspect of the present disclosure is used. In this way a highly dense nanotube fabric layer is used to prevent the second conductive layer 620 from electrically shorting to the first conductive layer 610 while still preserving the benefits of using a comparatively less dense nanotube fabric layer within the two terminal nanotube switching device.

Passivation Through the Use of a Sacrificial Material

In another aspect of the present disclosure, a carbonic nanolayer is passivated by using a sacrificial filler material. Within this aspect of the present disclosure, a sacrificial material is deposited over and allowed to penetrate a porous carbonic nanolayer prior to the deposition or formation of another material layer. This sacrificial material effectively fills in the pores of the carbonic nanolayer, preventing the other material layer from penetrating the carbonic nanolayer during a fabrication process. Once the other material layer is deposited or formed, the sacrificial material is etched away, allowing the carbonic nanolayer to function.

FIGS. 7A-7J illustrate a method of passivating a nanotube fabric layer through the use of a sacrificial filler material.

Referring now to FIG. 7A, in a first process step 700 a first conductive layer 710 is provided. Referring now to FIG. 7B, in a second process step 701 a porous nanotube fabric layer 730 is deposited over the first conductive layer 710. Referring now to FIG. 7C, in a third process step 702 a sacrificial material 740—such as, but not limited to, phospho silicate glass (PSG) oxide, spin on glass, a physical vapor deposition (PVD) of germanium, or a sacrificial polymer—is flowed over the porous nanotube fabric layer 730 such that it substantially permeates porous nanotube fabric layer 730 forming combined nanotube fabric/sacrificial material layer 730′. Referring now to FIG. 7D, in a fourth process step 703, excess sacrificial material 740 is etched (e.g., dry etching such as reactive ion etching) to remove any material overflowing the top of layer 730′.

It should be noted that while FIG. 7C (and subsequent figures) depicts sacrificial material 740 as essentially completely penetrating nanotube fabric layer 730, the methods of the present disclosure are not limited in this regard. Indeed, as will become evident in the following description of this aspect of the present disclosure, the depth to which the sacrificial material 740 penetrates the nanotube fabric layer 730 is not important so long as the sacrificial material 740 forms a barrier within the nanotube fabric layer which prevents an adjacent material layer from penetrating. Similarly, while FIG. 7C depicts sacrificial material 740 overflowing the nanotube fabric layer (necessitating process step 703 depicted in FIG. 7D), the methods of the present disclosure are not limited in this regard. Indeed, it will be obvious to those skilled in the art that in some applications a sacrificial material could be deposited in such a way that it does not overflow nanotube fabric layer 730, eliminating the need for process step 703.

Referring now to FIG. 7E, in a fifth process step 704, a second conductive layer 720 is deposited over the combined nanotube fabric/sacrificial material layer 730′. As the sacrificial material 740 substantially fills in the pores of the original nanotube fabric layer 730, second conductive layer 720 does not seep into the combined nanotube fabric/sacrificial material layer 730′.

Referring now to FIG. 7F, in a sixth process step 705 a hard mask layer 750—such as, but not limited to, an amorphous carbon layer—is deposited in such a way as to define a plurality of individual two terminal switching devices. Referring now to FIG. 7G, in a seventh process step 706, an etch process is used to remove those portions of first conductive layer 710, combined nanotube fabric/sacrificial material layer 730′, and second conductive layer 720 not covered by hard mask layer 750. In this way, three individual nanotube switching devices 760 a, 760 b, and 760 c are realized, each comprising a first conductive layer 710′, a patterned combined nanotube fabric/sacrificial material layer 730″, and a second conductive layer 720′. It should be noted that in some embodiments, sacrificial material 740—in addition to passivating the nanotube fabric layer 730 during the fabrication process—may also provide structural integrity to the individual two terminal nanotube switching elements 760 a, 760 b, and 760 c during the fabrication process. Referring now to FIG. 7H, in an eighth process step 707, the hard mask layer (750 in FIG. 7G) is removed.

Referring now to FIG. 7I, in a ninth process step 708, a wet etch process—such as, but not limited to, a hydrofluoric etch—is used to volatize and remove sacrificial material 740 through the exposed sides of each combined nanotube fabric/sacrificial material layer 730″ in each of individual nanotube switching elements 760 a, 760 b, and 760 c. In this way each of the individual nanotube switching devices (760 a, 760 b, and 760 c) is left with a patterned passivated nanotube fabric layer 730′″. Referring now to FIG. 7J, in a final process step 709, a dielectric material 770—such as, but not limited to, silicon nitride (SiN)—is deposited over the individual nanotube switch elements 760 a, 760 b, and 760 c.

In this way, a sacrificial material is flowed over a nanotube fabric layer and is used to passivate—as well as, in some embodiments, provide structural support for—the nanotube fabric layer as it is etched into individual narrow blocks to form a plurality of two terminal nanotube switch elements.

FIGS. 8A-8K illustrate another method of passivating a nanotube fabric layer through the use of a sacrificial filler material wherein the sacrificial material is volatized and removed through a non-hermetic material layer.

Referring now to FIG. 8A, in a first process step 800 a first conductive layer 810 is provided. Referring now to FIG. 8B, in a second process step 801 a porous nanotube fabric layer 830 is deposited over the first conductive layer 810. Referring now to FIG. 8C, in a third process step 802 a sacrificial material 840—such as, but not limited to, phospho silicate glass (PSG) oxide, spin on glass, a physical vapor deposition (PVD) of germanium, or a sacrificial polymer—is flowed over the porous nanotube fabric layer 830 such that it substantially permeates porous nanotube fabric layer 830. Referring now to FIG. 8D, in a fourth process step 803, the combined nanotube fabric/sacrificial material layer 830′ is etched to remove any material overflowing the top of the layer 830′.

It should be noted that while FIG. 8C (and subsequent figures) depicts sacrificial material 840 as essentially completely penetrating nanotube fabric layer 830, the methods of the present disclosure are not limited in this regard. Indeed, as will become evident in the following description of this aspect of the present disclosure, the depth to which the sacrificial material 840 penetrates the nanotube fabric layer 830 is not important so long as the sacrificial material 840 forms a barrier within the nanotube fabric layer which prevents an adjacent material layer from penetrating. Similarly, while FIG. 8C depicts sacrificial material 840 overflowing the nanotube fabric layer (necessitating process step 803 depicted in FIG. 8D), the methods of the present disclosure are not limited in this regard. Indeed, it will be obvious to those skilled in the art that in some applications a sacrificial material could be deposited in such a way that it does not overflow nanotube fabric layer 830, eliminating the need for process step 803.

Referring now to FIG. 8E, in a fifth process step 804, a non-hermetic conductive layer 820—that is a conductive layer which is substantially porous, such as, but not limited to, a physical vapor deposition (PVD) of titanium nitride (TiN), tantalum nitride (TaN), a tungsten (W), or a tungsten nitride (WN)—is deposited over the combined nanotube fabric/sacrificial material layer 830′. As the sacrificial material 840 substantially fills in the pores of the original nanotube fabric layer 830, the non-hermetic conductive layer 820 does not seep into the combined nanotube fabric/sacrificial material layer 830′.

Referring now to FIG. 8F, in a sixth process step 805 a hard mask layer 850—such as, but not limited to, an amorphous carbon layer—is deposited in such a way as to define a plurality of individual two terminal switching devices. Referring now to FIG. 8G, in a seventh process step 806, an etch process is used to remove those portions of first conductive layer 810, combined nanotube fabric/sacrificial material layer 830′, and non-hermetic conductive layer 820 not covered by hard mask layer 850. In this way, three individual nanotube switching devices 860 a, 860 b, and 860 c are realized, each comprising a first conductive layer 810′, a patterned combined nanotube fabric/sacrificial material layer 830″, and a non-hermetic conductive layer 820′. It should be noted that in some embodiments, sacrificial material 840—in addition to passivating the nanotube fabric layer 830 during the fabrication process—may also provide structural integrity to the individual two terminal nanotube switching elements 860 a, 860 b, and 860 c during the fabrication process. Referring now to FIG. 8H, in an eighth process step 807, the hard mask layer (850 in FIG. 8G) is removed.

Referring now to FIG. 8I, in an ninth process step 808, a dielectric material 870—such as, but not limited to, silicon nitride (SiN)—is deposited over the individual nanotube switch elements 860 a, 860 b, and 860 c. As the sacrificial material 840 substantially fills in the pores of the original nanotube fabric layer 830, the dielectric material 870 does not encroach into the sides of the combined nanotube fabric/sacrificial material layer 830″ within each of the nanotube switching devices 860 a, 860 b, and 860 c.

Referring now to FIG. 8J, in a tenth process step 809, a via (880 a, 880 b, and 880 c) is formed through dielectric material 870 over each of the individual nanotube switching elements (860 a, 860 b, and 860 c, respectively) such as to expose the non-hermetic conductive layer 820′ of each element. Referring now to FIG. 8K, in a final process step 811, a wet etch process—such as, but not limited to, a hydrofluoric etch—is used to volatize the sacrificial material 840 through the non-hermetic conductive layer 820′ within each of the nanotube fabric layers 830″ in each of individual nanotube switching elements (860 a, 860 b, and 860 c). The porous nature of the non-hermetic conductive layers 820′ allows the wet etch process to access the combined nanotube fabric/sacrificial material layer 830″ within each of the individual nanotube switching devices (860 a, 860 b, and 860 c) and dissolve and remove sacrificial material 840. In this way each of the individual nanotube switching devices (860 a, 860 b, and 860 c) is left with a patterned passivated nanotube fabric layer 830′″.

In this way, a sacrificial material is flowed over a nanotube fabric layer and is used to passivate—as well as, in some embodiments, provide structural support for—the nanotube fabric layer as it is etched into individual narrow blocks to form a plurality of two terminal nanotube switch elements.

FIGS. 9A-9M illustrate a method of passivating a nanotube fabric layer through the use of a sacrificial filler material wherein the sacrificial material is volatized during the formation of individual two terminal nanotube switching elements.

Referring now to FIG. 9A, in a first process step 901 a first conductive layer 910 is provided. Referring now to FIG. 9B, in a second process step 902 a porous nanotube fabric layer 930 is deposited over the first conductive layer 910. Referring now to FIG. 9C, in a third process step 903 a sacrificial material—such as, but not limited to, phospho silicate glass (PSG) oxide, spin on glass, a physical vapor deposition (PVD) of germanium, or a sacrificial polymer—is flowed over the porous nanotube fabric layer 930 such that it substantially permeates porous nanotube fabric layer 930, forming combined nanotube fabric/sacrificial material layer 930′.

It should be noted that while FIG. 9C (and subsequent figures) depicts the sacrificial material as essentially completely penetrating combined nanotube fabric/sacrificial material layer 930′, the methods of the present disclosure are not limited in this regard. Indeed, as will become evident in the following description of this aspect of the present disclosure, the depth to which the sacrificial material penetrates the combined nanotube fabric/sacrificial material layer 930 is not important so long as the sacrificial material 940 forms a barrier within the nanotube fabric layer which prevents an adjacent material layer from penetrating.

Referring now to FIG. 9D, in a fourth process step 904, a second conductive layer 920 is deposited over the combined nanotube fabric/sacrificial material layer 930′. As the sacrificial material substantially fills in the pores of the original nanotube fabric layer 930, second conductive layer 920 does not seep into the combined nanotube fabric/sacrificial material layer 930′.

Referring now to FIG. 9E, in a fifth process step 905 a first hard mask layer 950—such as, but not limited to, an amorphous carbon layer—is deposited in such a way as to define a plurality of narrow strips. Referring now to FIG. 9F, in a sixth process step 906, an etch process is used to remove those portions of first conductive layer 910, combined nanotube fabric/sacrificial material layer 930′, and second conductive layer 920 not covered by first hard mask layer 950. In this way, three long and narrow strips 960 a, 960 b, and 960 c are realized, each comprising a first conductive layer 910′, a patterned combined nanotube fabric/sacrificial material layer 930″, and a second conductive layer 920′. It should be noted that in some embodiments, the sacrificial material—in addition to passivating the nanotube fabric layer 930 during the fabrication process—may also provide structural integrity to the intermediate structures formed during the fabrication process (that is, long narrow strips 960 a, 960 b, and 960 c).

Referring now to FIG. 9G, in a seventh process step 907, the first hard mask layer (950 in FIG. 9F) is removed. Referring now to FIG. 9H, in an eighth process step 908, a dielectric material 970—such as, but not limited to, silicon nitride (SiN)—is deposited over long and narrow strips 960 a, 960 b, and 960 c.

Referring now to FIG. 9I, in a ninth process step 909 a second hard mask layer 950′—such as, but not limited to, an amorphous carbon layer—is deposited in such a way as to define a plurality of individual nanotube switching elements. Referring now to FIG. 9J, in a tenth process step 911, an etch process is used to remove those portions of first conductive layer 910′, combined nanotube fabric/sacrificial material layer 930″, and second conductive layer 920′ not covered by second hard mask layer 950′. In this way, a plurality of individual two terminal nanotube switching elements 960 a′, 960 b′, and 960 c′-960 c′″″ (additional nanotube switching elements in line with elements 960 a′ and 960 b′ and analogous to elements 960 c″-960 c′″″ are not visible in FIG. 9J, but would be present) are formed from three long and narrow strips 960 a, 960 b, and 960 c, each comprising a first conductive layer 910″, a patterned combined nanotube fabric/sacrificial material layer 930′″, and a second conductive layer 920′. Each row of two terminal nanotube switching elements 960 a′, 960 b′, and 960 c′-960 c′″″ remains coated in a layer of etched dielectric material 970′.

Referring now to FIG. 9K in an eleventh process step 912, the second hard mask layer (950′ in FIG. 9J) is removed.

Referring now to FIG. 9L, in a twelfth process step 913, a wet etch process—such as, but not limited to, a hydrofluoric etch—is used to volatize and remove the sacrificial material through the exposed sides of each combined nanotube fabric/sacrificial material layer 930′″ in each of individual nanotube switching elements 960 a′, 960 b′, and 960 c′-960 c′″″. In this way each of the individual nanotube switching devices (960 a′, 960 b′, and 960 c′-960 c′″″) is left with a patterned passivated nanotube fabric layer 930″″.

Referring now to FIG. 9M, in a final process step 914, a dielectric material 970″—such as, but not limited to, silicon nitride (SiN)—is deposited over individual nanotube switching elements 960 a′, 960 b′, and 960 c′-960 c′″″.

In this way, a sacrificial material is flowed over a nanotube fabric layer and is used to passivate—as well as, in some embodiments, provide structural support for—the nanotube fabric layer as it is etched into individual narrow blocks to form a plurality of two terminal nanotube switch elements.

Passivation Through the Use of a Non-Sacrificial Material

In another aspect of the present disclosure, a carbonic nanolayer is passivated by using a non-sacrificial filler material. Within this aspect of the present disclosure, a non-sacrificial material is deposited over and allowed to penetrate a porous carbonic nanolayer prior to the deposition of another material layer. This non-sacrificial material effectively forms a barrier within the carbonic nanolayer, preventing another material layer from penetrating completely through the carbonic nanolayer during a fabrication process. The non-sacrificial filler material is selected or deposited in such a way as to not adversely affect the switching function of the carbonic nanolayer. As such, a separate fabrication process step to remove the non-sacrificial material is not required.

FIGS. 10A-10D illustrate a method of passivating a nanotube fabric layer through the use of a non-sacrificial filler material.

Referring now to FIG. 10A, in a first process step 1001 a first conductive layer 1010 is provided. Referring now to FIG. 10B, in a second process step 1002 a porous nanotube fabric layer 1030 is deposited over the first conductive layer 1010. Referring now to FIG. 10C, in a third process step 1003 a filler material 1040—such as, but not limited to, amorphous carbon, silicon dioxide (SiO₂), and silicon nitride (SiN)—is flowed over the porous nanotube fabric layer 1030 such that it flows into and forms a barrier within nanotube fabric layer 1030.

Referring now to FIG. 10D, in a fourth process step 1004, a second conductive layer 1020 is deposited over nanotube fabric layer 1030. While nanotube fabric layer 1030 permits second conductive layer 1020 to seep through the pores and voids present within the porous nanotube fabric layer 1030, the layer of filler material 1040 within the nanotube fabric layer 1030 prevents the second conductive layer 1020 from coming into physical (and electrical) contact with first conductive layer 1010.

It should be noted that while FIGS. 10C and 10D depict filler material 1040 as forming a barrier layer along the bottom of nanotube fabric layer 1030 and adjacent to first conductive layer 1010, the methods of the present disclosure are not limited in this regard. Indeed, as will become evident in the following description of this aspect of the present disclosure, the depth to which the sacrificial material 1040 penetrates the nanotube fabric layer 1030 is not important so long as the filler material 1040 forms a barrier within the nanotube fabric layer which prevents an adjacent material layer from penetrating completely and coming into physical contact with first conductive electrode 1010.

FIGS. 11A-11F illustrate a method of passivating a nanotube fabric layer through the use of a porous dielectric material. The formation and application of a porous dielectric material (such as, but not limited to, silicon dioxide aerogel and porous silica) are well known to those skilled in the art. Typically a dielectric material is infused with particles of a second material (typically an organic material) commonly termed a “porogen” by those skilled in the art. An etching process or an anneal process is typically employed to remove the porogen material after the dielectric material has been deposited, leaving behind a plurality of voids or pores within the formed dielectric material layer.

Referring now to FIG. 11A, in a first process step 1101, a first conductive layer 1110 is provided. Referring now to FIG. 11B, in a second process step 1102, a nanotube fabric layer 1130 comprising a plurality of individual nanotube elements 1130 a is formed over first conductive layer 1110. Referring now to FIG. 11C, in a third process step 1103, a dielectric material 1140 infused with a plurality of porogens 1140 a is applied and allowed to penetrate nanotube fabric layer 1130. Referring now to FIG. 11D, in a fourth process step 1104 the dielectric material layer 1140 is etched to remove any material overflowing the top of nanotube fabric layer 1130.

Referring now to FIG. 11E, in a fifth process step 1105 an etching process is used to volatize and remove the plurality of porogens 1140 a within porous dielectric material 1140. The volatizing and removal of porogens 1140 a within process step 1105 results in a plurality of voids or pores 1140 b within porous dielectric material 1140.

In a sixth process step 1106, a second conductive layer 1120 is deposited over the nanotube fabric layer 1130. The porous nanotube fabric layer 1130, now at least partially infused within the porous dielectric material 1140, is substantially passivated, and second conductive layer 1120 does not encroach the nanotube fabric layer 1130.

The plurality of voids 1140 b within porous dielectric material 1140 allows for a plurality of individual nanotube junctions 1130 b (that is, the areas within the nanotube fabric layer where two or more individual nanotube elements meet) to operate freely. Thus, while the nanotube fabric layer 1130 is substantially passivated and does not permit conductive layer 1120 to penetrate through, the overall switching operation is still able to function within the void areas 1140 b.

FIGS. 12A-12F illustrate a method of passivating a nanotube fabric layer through the use of a room temperature chemical vapor deposition (RTCVD) process.

Referring now to FIG. 12A, in a first process step 1201 a first conductive layer 1210 is provided. Referring now to FIG. 12B, in a second process step 1202 a porous nanotube fabric layer 1230 comprising a plurality of individual nanotube elements 1230 a is deposited over first conductive layer 1210. Referring now to FIG. 12C, in a third process step 1203 a gaseous filler material 1240—such as, but not limited to, tetraethyl orthosilicate (TEOS)—is flowed over nanotube fabric layer 1240 at room temperature. Referring now to FIG. 12D, in a fourth process step 1204 ultraviolet (UV) radiation 1250 is used to convert the gaseous filler material (1240 in FIG. 12C) into a liquid filler material 1240′.

Referring now to FIG. 12E, in a fifth process step 1205 the liquid filler material (1240′ in FIG. 12D) is allowed to penetrate nanotube fabric layer 1230, and an anneal process is used to convert the liquid filler material (now in place within the nanotube fabric layer 1230) into a solid state 1240″. In this way, a filler material 1240″ forms a barrier layer within nanotube fabric layer 1230, essentially passivating nanotube fabric layer 1230 as will be shown in final process step 1206 (depicted in FIG. 12F) below.

Referring now to FIG. 12F, in a final process step 1206 a second conductive layer 1220 is deposited over nanotube fabric layer 1230. While second conductive layer 1220 penetrates partially through nanotube fabric layer 1230, filler material 1240″ prevents it from coming into physical or electrical contact with first conductive layer 1210.

FIGS. 13A-13E illustrate a method of passivating a nanotube fabric layer through the use of a non-directional sputter deposition process.

Referring now to FIG. 13A, in a first process step 1301 a first conductive layer 1310 is provided. Referring now to FIG. 13B, in a second process step 1302 a porous nanotube fabric layer 1330 comprising a plurality of individual nanotube elements 1330 a is deposited over first conductive layer 1310. Referring now to FIG. 13C, in a third process step 1303 filler material particles 1340 b are deposited over the top of nanotube fabric layer 1330 via a non-directional sputter deposition process.

Sputter deposition processes are well known to those skilled in the art. As depicted in exemplary process step 1303 in FIG. 13C, a wafer of filler material 1340—such as, but not limited to, titanium nitride (TiN)—is bombarded with ions 1350—such as, but not limited to argon (Ar). This bombardment ejects particles 1340 b (or in some cases individual atoms) of the filler material 1340. In a typical directional sputter process, an electric field is used to direct the trajectory of the ejected filler material particles 1340 b. For example, a typical directional sputter process might apply an electric field over the nanotube fabric layer 1330 such that the ejected filler material particles 1340 b impacted the nanotube fabric layer substantially perpendicular to the layer itself. In this way, a substantial number of the filler material particles 1340 b could be expected to penetrate through the porous nanotube fabric layer 1330.

Within the methods of the present disclosure, however, a non-directional sputter deposition process is used. That is, the ejected filler material particles 1340 b are allowed to fly away from the filler material wafer 1340 in random trajectories. In this way, very few of the ejected filler material particles 1340 b will penetrate the porous nanotube fabric layer 1330 and most of the ejected filler material particles 1340 b will simply form a layer over the top surface of nanotube fabric layer 1330.

Referring now to FIG. 13D, in a fourth process step 1304 this top layer of ejected filler material particles 1340 b can be seen covering the top of nanotube fabric layer 1330. Referring now to FIG. 13E, in a final process step 1305 a second conductive layer 1320 is deposited over nanotube fabric layer 1330. The layer of ejected filler material particles 1340 b serve to limit the encroachment of the second conductive layer 1320, preventing the layer from seeping into nanotube fabric layer 1330 and coming into physical or electrical contact with first conductive layer 1310.

In this way nanotube fabric layer 1330 is passivated with a layer of filler material particles 1340 b deposited via a non-directional sputter deposition process, preventing the encroachment of an adjacent material layer 1320 while preserving the switching function of the nanotube fabric layer 1330 itself.

Passivation Through the Use of Nanoscopic Particles

In another aspect of the present disclosure, a passivated carbonic nanolayer is comprised of a first plurality of carbon structures (such as, but not limited to, carbon nanotubes, buckyballs, and nano-scopic graphene flecks) and a second plurality of nanoscopic particles. The nanoscopic particles limit the overall porosity of the carbonic nanolayer—which limits the degree to which another material layer can penetrate the carbonic nanolayer—while preserving the switching function of the carbonic nanolayer itself. In this way, the overall density of a carbonic nanolayer can be increased without increasing the density of the carbon structures.

FIG. 14 illustrates the formation of a two terminal nanotube switching devices including a nanotube fabric layer which comprises both individual nanotube elements and nanoscopic particles. A first volume 1430 of individual nanotube elements 1430 a is combined with a second volume 1440 of nanoscopic particles 1440 a to form an application solution 1450 which comprises both individual nanotube elements 1430 a and nanoscopic particles 1440 a. Specific values for the first volume 1430 and the second volume 1440 are selected such that a desired ratio of individual nanotube elements 1430 a to nanoscopic particles 1440 a is realized. For instance, in one non-limiting example an optimal ratio of individual nanotube elements 1430 a to nanoscopic particles 1440 a for the formation of two terminal nanotube switching devices would be 1:1.

In some embodiments it may be desirable to combine both the individual nanotube elements 1430 a and the nanoscopic particles 1440 a into a liquid medium such as, but not limited to, water to form application solution 1450. Once combined, the volume of the liquid medium can then be adjusted as to provide a specific concentration (that is the ratio of individual nanotube elements and nanoscopic particles to liquid) optimal for the application of said solution 1450 over first conductive layer 1410 to form a combined nanotube fabric/nanoscopic particle layer 1460 (as depicted by structure 1401). Further, in some embodiments application solution 1450 is applied to first conductive layer 1410 via a spin coating process. However, the methods of the present disclosure are not limited in this regard. Indeed, application solution 1450 could be applied through a plurality of methods including, but not limited to, spray coating.

As depicted in structure 1401, application solution 1450 is deposited over first conductive layer 1410 to form composite switching layer 1460. Within the methods of the present disclosure, nanoscopic particles 1440 a serve to limit the porosity between individual nanotube elements 1430 a within composite switching layer 1460. As such, as second conductive layer 1420 is applied over composite switching layer 1460—resulting in structure 1402—the encroachment of second conductive layer 1420 into composite switching layer 1460 is significantly limited, preventing second conductive layer 1420 from seeping through composite switching layer 1460 and making physical or electrical contact with first conductive layer 1410.

In one embodiment of this aspect of the present disclosure, nanoscopic particles 1440 a are a colloidal dispersion of inert (that is, non-conductive) silica particles. However, the methods of the present disclosure are not limited in this regard. Indeed, nanoscopic particles 1440 a can take a plurality of forms depending on the needs of an application or structure in which the methods of the present disclosure are employed. The nanoscopic particles 1440 a may be spherical, oblong, square, irregular, or any other shapes as would be readily apparent to those skilled in the art. The nanoscopic particles 1440 a may have at least one dimension that is in the nanometer size. For example, the nanoscopic particles 1440 a may have at least one dimension which is less than 1000 nm, 500 nm, 400 nm, 300 nm, 200 nm, 100 nm, 50 nm, 40 nm, 30 nm, 20 nm, 10 nm, 5 nm, or 1 nm. In certain embodiments, the nanoscopic particles 1440 a may be individual atoms, molecules, or ions.

Nanoscopic particles 1440 a can interact covalently or non-covalently to another nanoscopic material, for example, carbon nanotubes. In certain embodiments, the nanoscopic particles 1440 a may be miscible with the nanotube elements 1430 a and form a continuous material around the individual nanotube elements 1430 a. In some other embodiments, the nanoscopic particles 1440 a may be inert to the nanotube elements 1430 a and remain in the same form as initially introduced into the mixture 1450 and therefore non-miscible. In yet some other embodiments, the nanoscopic particles 1440 a may be partially miscible with the nanotube elements 1430 a and form a semi-miscible mixture with the nanotubes.

Furthermore, in certain embodiments, the choice of such nanoscopic particles 1440 a can include a material or materials that can be formed with a uniform particle size. In certain applications, the choice of a nanoscopic particle can include a material or materials which can be fabricated as individual particles within certain dimensions. For example, an application may require a nanoscopic particle wherein individual particles are not larger than some fraction of a device feature size.

The choice of such nanoscopic particles can include any material or materials which do not adversely affect the switching operation (that is, the changing from one nominal nonvolatile resistive state to another) of the composite article. In fact, in certain embodiments, the nanoscopic particles 1440 a may improve switching operation by lowering the voltage needed for the composite article to change its resistance.

In some other embodiments, inorganic nanoparticles can be utilized. For example, silicon based materials (such as, but not limited to silicon oxide and silicon nitride) can be used for said nanoscopic particles 1440 a.

In some embodiments, one or more non-conductive allotropes of carbon (such as, but not limited to, diamond, carbon black, and fullerenes) can be used for said nanoscopic particles 1440 a.

In certain embodiments, nanoscopic particles 1440 a can include a mixture of different nanoscopic materials, such as any combination of nanoscopic particles 1440 a described above.

The nanoscopic particles 1440 a can be obtained by numerous different ways. For example, carbon particles having substantially uniform volume can be obtained through the process described below. Methods for obtaining other desired nanoscopic materials 1440 a will be readily apparent to those skilled in the art.

-   -   In a first processing step, reacting a volume of carbon black         material with an oxidizing agent (such as, but not limited to,         nitric acid) to form a carbon slurry in order to decrease the         size of carbon black particles and further remove any metallic         contaminants (via solubilization). The first processing step may         be aided by further introducing other acids, such as         hydrochloric acid.     -   In a next processing step, filtering the carbon slurry formed in         the first process step at low pH (for example, but not limited         to, via cross-flow membranes) to remove any solubilized         impurities     -   In a next processing step, increasing pH level of the carbon         slurry to realize a homogeneous and stable colloidal system (in         some operations, a sonication process may be used to improve         homogeneity)     -   In a next processing step, filtering the realized homogeneous         and stable colloidal system through a train of filters to remove         any particles which could lead to defects in the spin coated         film (in some operations, for example, said system would be         passed through filters with pores as small as 10 nm or 5 nm or         other filters with the smallest pore size available)

FIGS. 15A-15F illustrate a method of further passivating a nanotube fabric layer comprised of individual nanotube elements and nanoscopic particles through the use of a room temperature chemical vapor deposition (RTCVD) process.

Referring now to FIG. 15A, in a first process step 1501 a first conductive layer 1510 is provided. Referring now to FIG. 15B, in a second process step 1502 a porous composite switching layer 1530 comprising a first plurality of individual nanotube elements 1530 a and a second plurality of nanoscopic particles 1530 b is deposited over first conductive layer 1510. Referring now to FIG. 15C, in a third process step 1503 a gaseous filler material 1540—such as, but not limited to, tetraethyl orthosilicate (TEOS)—is flowed over composite switching layer 1530 at room temperature. Referring now to FIG. 15D, in a fourth process step 1504 ultraviolet (UV) radiation 1550 is used to convert the gaseous filler material (1540 in FIG. 15C) into a liquid filler material 1540′.

Referring now to FIG. 15E, in a fifth process step 1505 the liquid filler material (1540′ in FIG. 15D) is allowed to penetrate composite switching layer 1530, and an anneal process is used to convert the liquid filler material (now in place within the composite switching layer 1530) into a solid state 1540″. In this way, a filler material 1540″ forms a barrier layer within composite switching layer 1530, essentially passivating composite switching layer 1530 as will be shown in final process step 1506 (depicted in FIG. 15F) below.

Referring now to FIG. 15F, in a final process step 1506 a second conductive layer 1520 is deposited over composite switching layer 1530. While second conductive layer 1520 penetrates partially through composite switching layer 1530, this encroachment is limited by the presence of nanoscopic particles 1530 b (as described in the discussion of FIG. 14 above), and the barrier formed by filler material 1540″ further prevents second conductive layer 1520 from coming into physical or electrical contact with first conductive layer 1510.

FIGS. 16A-16E illustrate a method of further passivating a nanotube fabric layer comprising individual nanotube elements and nanoscopic particles through the use of a non-directional sputter deposition process.

Referring now to FIG. 16A, in a first process step 1601 a first conductive layer 1610 is provided. Referring now to FIG. 16B, in a second process step 1602 a porous composite switching layer 1630 comprising a first plurality of individual nanotube elements 1630 a and a second plurality of nanoscopic particles 1630 b is deposited over first conductive layer 1610. Referring now to FIG. 16C, in a third process step 1603 filler material particles 1640 b are deposited over the top of composite switching layer 1630 via a non-directional sputter deposition process.

As discussed in the detailed description of FIGS. 13A-13E, sputter deposition processes are well known to those skilled in the art. A wafer of filler material 1640—such as, but not limited to, titanium nitride (TiN)—is bombarded with ions 1650—such as, but not limited to argon (Ar). This bombardment ejects particles 1640 a (or in some cases individual atoms) of the filler material 1640. In a typical directional sputter process, an electric field is used to direct the trajectory of the ejected filler material particles 1640 b. For example, a typical directional sputter process might apply an electric field over the composite switching layer 1630 such that the ejected filler material particles 1640 b impacted the nanotube fabric layer substantially perpendicular to the layer itself. In this way, a substantial number of the filler material particles 1640 b could be expected to penetrate through the porous composite switching layer 1630.

Within the methods of the present disclosure, however, a non-directional sputter deposition process is used. That is, the ejected filler material particles 1640 b are allowed to fly away from the filler material wafer 1640 in random trajectories. In this way, very few of the ejected filler material particles 1640 b will penetrate the porous composite switching layer 1630 and most of the ejected filler material particles 1640 b will simply form a layer over the top surface of composite switching layer 1630.

Referring now to FIG. 16D, in a fourth process step 1604 this top layer of ejected filler material particles 1640 b can be seen covering the top of composite switching layer 1630. Referring now to FIG. 16E, in a final process step 1605 a second conductive layer 1620 is deposited over composite switching layer 1630. While second conductive layer 1620 penetrates partially through composite switching layer 1630, this encroachment is limited by the presence of nanoscopic particles 1630 b (as described in the discussion of FIG. 14 above), the layer of ejected filler material particles 1640 b further serves to limit the encroachment of second conductive layer 1620, preventing the layer from seeping into composite switching layer 1630 and coming into physical or electrical contact with first conductive layer 1610.

In this way composite switching layer 1630 is passivated with a layer of filler material particles 1640 b deposited via a non-directional sputter deposition process, preventing the encroachment of an adjacent material layer 1620 while preserving the switching function of the composite switching layer 1630 itself.

Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. It is preferred, therefore, that the present invention not be limited by the specific disclosure herein. 

What is claimed is:
 1. A method for forming a carbonic nanolayer based device, comprising: forming a carbonic nanolayer, said carbonic nanolayer comprising a plurality of carbon structures; flowing a filler material over said carbonic nanolayer such that said filler material penetrates said carbonic nanolayer to form a barrier layer; and depositing a non-hermetic material layer such that said carbonic nanolayer and said non-hermetic material layer have longitudinal axes that are substantially parallel; and volatizing and removing at least a portion of said filler material from said carbonic nanolayer through said non-hermetic material layer.
 2. The method of claim 1 wherein said barrier layer limits the encroachment of said material layer into said carbonic nanolayer.
 3. The method of claim 1 further comprising etching away excess filler material after said flowing and prior to said depositing.
 4. The method of claim 1 further comprising etching at least one of said material layer, said barrier layer, and said carbonic nanolayer to form a plurality of individual carbonic nanolayer based devices prior to said volatizing.
 5. The method of claim 4 wherein said barrier layer provides structural support to said carbonic nanolayer during said etching.
 6. The method of claim 1 wherein said non-hermetic material comprises a physical vapor deposited titanium nitride (TiN), tantalum nitride (TaN), or tungsten (W).
 7. The method of claim 1 further comprising at least partially encapsulating at least one of said material layer, said barrier layer, and said carbonic nanolayer within a dielectric material layer prior to said volatizing.
 8. The method of claim 7 wherein said dielectric material layer comprises silicon nitride (SiN).
 9. The method of claim 1 wherein said volatizing is performed using a wet etch process.
 10. The method of claim 9 wherein said wet etch process is a hydrofluoric etch process.
 11. The method of claim 1 wherein said filler material is selected from the group consisting of phosphosilicate glass (PSG) oxide, amorphous carbon, silicon dioxide (SiO2), and silicon nitride (SiN).
 12. The method of claim 1 where said filler material is a porous dielectric.
 13. The method of claim 12 wherein said porous dielectric is one of silicon dioxide aerogel or porous silica.
 14. The method of claim 1 wherein said barrier layer is formed through a room temperature physical vapor deposition (RTPVD) process.
 15. The method of claim 14 wherein said filler material comprises tetraethyl orthosilicate (TEOS).
 16. The method of claim 1 wherein said barrier layer is formed through a non-directional sputter deposition process.
 17. The method of claim 16 wherein said filler material comprises titanium nitride (TiN).
 18. The method of claim 1 wherein said carbon structures are selected from the group consisting of single wall carbon nanotubes, multi-wall carbon nanotubes, functionalized carbon nanotubes, oxidized carbon nanotubes, buckyballs, graphene sheets, nano-scopic grapheme flecks, and graphene oxide. 